Installing Sealing Ring For Intermediate Shaft
- Check crankcase bore for sharp edges. Break off (deburr) any sharp edges on the crankcase bore (intermediate shaft flange) with polishing cloth or an oilstone.
- Grease the new sealing ring slightly with Optimoly MP3 (available from Porsche Parts Service) and insert in the groove of the intermediate shaft flange.NOTE:
- The sealing ring must not be twisted and must not be pulled over sharp edges of the flange.
- Position intermediate shaft flange on the bore and affix with new micro-encapsulated hexagon-head bolts.NOTE:
- Do not exert any pressure on the threaded pin when pushing in the intermediate shaft flange, as the threaded pin might otherwise be pressed inward into the intermediate shaft.
- As soon as the threaded pin projects at the intermediate shaft flange, screw the new lock nut into position.
- Position and align special tool retaining device 9642. See Fig 1. Centre intermediate shaft and intermediate shaft flange by turning the crankshaft to and fro a little (max. 2° to 3°, remove dowel pin from the belt pulley first).
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:- It must be possible to insert the intermediate shaft flange almost completely into the intermediate shaft bore by hand.
- Tighten the three micro-encapsulated M6 x 20 hexagon-head bolts evenly. See Fig 2.
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tightening torque 10 Nm (7.5 ft.lb)
- Tighten lock nut M8 x 1 with the socket wrench 9110. At the same time, have a second person counter with a suitable screwdriver in the slotted threaded pin. See Fig 3.
Tightening torque 11 Nm (8 ft.lb)
- Fit new sealing rings to both chain tensioners, screw in and tighten.
Tightening torque 80 Nm (59 ft.lb)
- Fill in engine oil. Refer to ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE
or CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003
.
.NOTE:
- Replace screws for the double-mass flywheel and drive plate for the torque converter.
- Fit double-mass flywheel or drive plate for the torque converter.NOTE:
- In order to avoid deforming the thrust plate housing, always tighten the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
- Fit the clutch pressure plate with drive plate.
- Install manual transmission or Tiptronic transmission.
TIGHTENING TORQUES - SEALING RING FOR INTERMEDIATE SHAFT
| Location | Thread | Tightening torque (Nm) (ft.lb.) |
|---|---|---|
| Oil drainage plug | M18 x 1.5 | 50 (37) |
| Hexagon-head bolts, intermediate shaft flange | M6 x 20 | 10 (7.5) |
| Lock nut, intermediate shaft | M8 x 1 | 12 (9) |
| Chain tensioner | M27 x 2 | 80 (59) |
| Pan-head screw, clutch pressure plate | M8 x 16 | 23 Nm (17) |
| Screw for DMF | M10 x 50 x 1 | 25 (19) + 120° torque angle; observe TI 3/02 Serv. No. 1363! |
| Screw for torque converter drive plate | M10 x 25 x 1 | 25 (19) + 90° or 120° torque angle; observe TI 3/02 Serv. No. 1363! |